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ProFoss for in-line process analysis of dairy powder

ProFoss provides non destructive analysis of dairy powder directly in the process line without bypass. A dedicated sample interface feeds data to an analyser housed in a robust cabinet mounted at the relevant location in
the production area, for example, after the secondary drying stage (i.e. fluid bed) to check final moisture content.
Results can be fed into your production/SCADA system and/or be presented on a screen in the production area for
rapid adjustments of your process. Precise instrument matching enhances method development, minimises implementation efforts and ensures calibration model transferability between analysers.

Sample

Parameters

Skim Milk Powder, Whole Milk Powder, Whey


Powder, WPC or Caseinate Powder

Moisture, protein & fat

Dedicated Analytical Solutions

Streamline your production


with High Resolution in-line analysis

Anyone in the plant can contribute to process control. Easyto-use calibration software options such as ISIcal allow
non-experts to develop or expand existing calibration with
automatic sample synchronization. Once calibrations have
been made, there is no need for further adjustments.

Achieve complete control of your dairy powder production


with ProFoss in-line sensor. Follow product composition more
closely with a continuous flow of real time results using high
resolution diode array technology. Installing ProFoss after the
secondary drying stage enables you to validate the moisture
content and make timely adjustments to meet specified final
product quality.

Quick and simple to implement


The High Resolution technology behind the accuracy of the
ProFoss system also has benefits when implementing the system. Because measurements can be relied on to be the same
across individual instruments and are highly stable over time,
you can reduce the time and money spent on installation of
individual analysers. The standardisation and stability of the
solution, as well as the intelligent FOSS calibration tool ISIcal,
makes it fast and easy for non-experts to develop or expand
calibrations and transfer them across units.

Improve your
business with accurate control
Profit opportunities are waiting to be found in your dairy
powder process, regardless of whether you are producing
Skim Milk Powder, Whole Milk Powder, Whey Powder, WPC
or Caseinate Powder. For instance, more accurate control of
moisture in the final dairy powder provides increased yield.
At the same time, improved product consistency can provide
new pricing options.

Profit improvement

Users of such solutions report a rapid return on investment


with a typical payback time of less than twelve months.
Advantages of dairy powder process control include improved
yield and profit based on:

A powder production with an output of 70,000 tons


per year moves moisture closer to target by 0.1 %
leading to a yield increase worth euro 147,000.

Optimised moisture content


Run production closer to specified targets
Consistent product quality
Higher value products for your customers
Increased energy efficiency
Reduced rework

Anyone can use it


With its user-friendly and low maintenance features, ProFoss
gives your production staff the perfect tool to maintain process
control for increased yield and improved consistency. Near
infrared, high resolution technology ensures a high level of
accuracy that you can rely on day in day out.

BEFORE

AFTER

COST REVENUE PROFIT

COST REVENUE PROFIT

Stretch your profit zone: Production costs can be


decreased and the higher product consistency will
increase your competitiveness.

How to improve your dairy powder production


Process analysis advantages
Production close to target specifications
Increased yield
Less rework and start up variation
Optimized mass-balance

Production closer to target

Reduce start up variation

Alarms you when production is out of spec

TARGET

Parameters
Moisture
Protein
Fat
In final dairy powder, the primary profit driver is to optimise the
moisture level to increase yield and
thereby revenue. Protein and fat
are secondary parameters, typically
used for validation of the final product quality.

TARGET

TARGET

Typical analyzer
Installation point

Dedicated
sample interface

Installation after the secondary


drying stage (e.g. fluid bed) in
order to validate and adjust final
moisture content

Spoon probe connected to analyser via fiber optics

Explosion certified according to


IECEx (ATEX)
Hygiene certified according to
USDA

True in-line no bypass no waste


No moving parts
No hygiene compromises

ProFoss High Resolution NIR technology


ProFoss is unique in employing a near infrared-based analysis
technology known as High Resolution diode array analysis. The
High Resolution technology ensures accuracy and reliability
with measurements based on a high density of data points.

Interface for integration to local control systems enables


automatic regulation (OPC, 4-20mA, Profibus etc communication).

Accurate and continuous results

Robust and low maintenance operation

Measurement accuracy is in line with traditional laboratory


analysis. However, results are presented continuously rather
than a few times per day giving the opportunity for immediate
adjustments to production. This together with the dedicated
dairy powder sample interface ensures you a total solution
optimal for your process.

The ProFoss system keeps on running to ensure high uptime


and minimal impact on daily production. Once calibrated,
there is no need for constant adjustments caused by drift or
other weaknesses. The high stability of the High Resolution
technology ensures the same accuracy day in and day out
without hidden operational costs.

ProFoss streamlines your


manufacturing process with:
High resolution diode array technology for accurate and
continuous analysis
Built-in instrument standardisation for quick and simple
implementation
Dedicated sample interfaces providing accuracy and rapid
implementation
Instant measurement of complete wavelength range for
direct measurement of fast moving samples
Quantitative and qualitative data for better in-line process
control
Consistent and uninterrupted analytical accuracy with Dual
lamp backup technology
Integrated intelligent FOSS calibration tool, ISIcal enables
anyone to develop calibrations

Intelligent calibration tool - ISIcal


Calibration is done either through WinISI or by using
the intelligent calibration tool, ISIcal. ISIcal requires
a minimum of user experience. Each time a reference sample is collected from the process, a button is
pressed on the analyzer to synchronize the scan with
the collected sample. Reference data is added and a
calibration is automatically developed (or an existing
calibration expanded with the new data). The ISIcal
tool automatically optimizes the calibration algorithms
by selecting the most reliable model for future use.

High Resolution near infrared technology gives you a clearer picture of your process. A high number of pixels (diode sensors) in the spectrum secures a
more detailed (accurate) and uniform (repeatable) analysis result.
High Resolution also enables manufacturing of "identical" (standardized) analyzers which stay the same over time (no drift).

Dedicated interfaces based


on reflectance technology

A standardised High Resolution analyser


A standardised analyser with transferable calibrations significantly reduces the implementation and maintenance costs.
Transferability is the solid foundation required for rapid implementation of an analyser into a complex process environment.
Furthermore, once a calibration has been developed, it can
be reused on other analysers. The key to achieving this is the
resolution of the analysers wavelength scale. The FOSS High
Resolution technology has one sensor for each nm measured,
securing 100% stability of the wavelength scale. In contrast,
with lower wavelength resolution, shifts of up to 7 8 nm
in the wavelength scale can occur, which will require major
updates of existing calibrations for each new analyser installed.

The ProFoss analyser for milk powder is available with dedicated interfaces based on reflectance technology. Measurements are done directly on the moving sample out of the fluid
bed. A high-intensity dual-lamp light source illuminates the
sample directly. The light interacts with the sample and the reflected light is measured by the diode array sensor. The backup
lamp in the dual lamp system secures uptime and analytical
precision is unchanged even after switching to a new lamp.
The complete wavelength range is measured instantaneously
enabling measurements to be accurately carried out even on
fast moving sample.
Calibrations are transferable between units ensuring easy expansion to other measurement points. Integration to process
regulations systems can be done through interfacing via OPC,
4-20mA, Profibus etc. communication.

RINA takes your


NIR support to the next level

FOSS support plans

RINA is a software suite for networking of the following ISIscan based instruments such as InfraXact, XDS, NIRSystem II
(Feed and Forage Analysers), ProFoss and Foodscan. The software allows you to centralize or outsource your NIR support,
which will lead to considerable cost savings and performance
improvements. Technically it consists of three parts, a server, a
network manager with access to internet and one or several
clients (NIR instruments).

FossCare is a partnership, where FOSS helps customers with preventive maintenance, remote instrument
monitoring, consultancy, training programs and downtime support. FOSS technicians work directly with the
customer to solve any problem that they encounter,
leading to maximum uptime and increased yield.
By participating in a Preventive Maintenance program,
focus is moved from fix it when it breaks to a predictable and proactive approach, reducing the cost
of unplanned downtime and emergency repairs and
increasing the equipment reliability and availability of
the solution.

Investing in a process analysis solution


With any process analysis solution you are effectively putting
your production in the hands of technology. FOSS is the right
partner to provide a reliable solution that will run day in, day
out and year after year.

Remote Monitoring and diagnostics

ProFoss is simple to install directly in the production line and


comes with a total service solution to help protect your investment. FossCare support plans offer the option of preventative
maintenance for maximum uptime and minimized repair costs

RINA is a remote instrument monitoring and diagnostics software that makes it easy for an internal or
external expert to precisely configure, monitor and
diagnose FOSS instruments from a remote location.
Calibration updates and bias corrections are easily
handled through the network and the system can be
monitored on a daily basis, allowing you to focus on
optimizing your production.

FOSS solutions offer:


Proven technology for precision and trouble-free operations
User-friendly interfaces allowing anyone in the plant to
contribute to process control
Service programs offering a range of options to suit your
business
Get your service in a timely manner by fully trained local
staff onsite and/or remotely through internet

FOSS Total Service Solutions


FOSS is committed to providing complete and
fully integrated solutions to our customers
Our relationship with you is a continuous
partnership, not a time-limited occurrence
FossCare Total Service Solutions are available
at multiple levels according to your needs

NEW:
Extended warranty on
new instruments with
a FossCare agreement

Secure your investment with a


FossCare Support Agreement
Let FOSS take care of you for a maximum return on your analytical investment. Get a four year warranty as part of the
new FossCare Premium Preventive Maintenance Agreement or two years as part of any other FossCare agreement. In
addition to the peace of mind afforded by the warranty period, the continual preventive maintenance pays off by keeping
your analytical instruments working perfectly every day, year after year.

Why preventive maintenance?


As with any analytical solution, it is essential that your FOSS instrument receives regular maintenance to ensure optimal
performance and extended lifetime. Avoiding expensive downtime is a matter of following factory standards and preventively replacing parts before they wear out. In turn, this helps ensure reliable and consistent results at the highest level.
Preventive and predictive maintenance combined with global support from 300 dedicated service, application, software
and calibration specialists keeps your instrument running perfectly all year round.

Benefits of a FossCareTM Support Agreement:

YEAR

WARRANTY
with all FossCare Premium
Preventive Maintenance
Agreements

Extended Warranty (two or four years depending on the chosen agreement)


Regular maintenance; the instrument is diagnosed, cleaned, adjusted, tested,
fine tuned and recalibrated
Minimal downtime
from replacing components before they are worn out
YEAR
WARRANTY
Consistent, accurate
and reliable results you can always trust
with FossCare Basic & Standard
Preventive Maintenance
Preventative maintenance
Agreements visits when it suits you (your business)
24/7 phone support - no need to worry about closing hours or PO
Low, fixed service budget prevents unexpected expenses
Discounts on additional services, spares, training, reagents, consumables and
software upgrades

Contact your local Foss office for more information.

Dedicated Analytical Solutions


7

Technical Specifications
ProFoss Reflection:
Analysis time:

5 50 ms / integration time; Average time per result 3 15 seconds

Measurement mode:

Reflection

Wavelength range:

1100 1650 nm

Detector:

InGaAs Diode array

Spectral dispersion:

1.1 nm / pixel

General:
Light source lifetime:

Dual lamp system = 17500 h

Software package:

ISIscan for instrument control; ISIcal for calibration development

Wavelength accuracy:

0.5 nm

Wavelength precision:

< 0.02 nm

Wavelength stability:

< 0.01 nm/C

Noise:

< 60 micro AU

Random Vibrations:

0.4 grms at 10 150 Hz according to IEC 60068-2-64


0.4 grms at 10 1250 Hz according to FOSS internal standard
(more information available on request)

Temperature:

-5 40C (23 104F). With purge -5 65C (23 149F)

Installation in ATEX zone:

0 40C (32 104F). With purge 0 65C (32 149F)

Purge air:

Flow rate minimum 5 l/min,


> 99.9% water free, > 99.9% free of oil and fine particles down to 0.3m

Ambient humidity:

10 90 % relative

Dimensions:

(w h d): 42 42 13.5 cm
(16.5 16.5 5.3 inches) + brackets to hold the unit

Weight:

25 kg / 55 lbs

Cabinet:

1.5 mm (lid 2.5mm) Stainless Steel EN 1.4301 (SS2333)

Protection:

IP69K 1) according to IEC 60529 and DIN 40050 part 9, NT ELEC 023

Communication:

Ethernet, OPC 4 - 20 mA, Profibus, RINA

Power supply:

Recommended isolated or conditioned line power


100 240 VAC, 50 60 Hz, 2.0 A, 150W

1) IP6x is the highest protection for dust entering the unit. IPx9K means protected against the effect of high-pressure water and/or steam cleaning at
high temperature.
8

Dedicated sample interfaces


Window reflection:
In-line analysis of paste, granulates, powdered products etc in pipes or
transport systems without bypass can be performed. The products pass
over the interface window. The window reflection interface can easily be
installed into the production line using standard GEA Tuchenhagen flowcells
or welding an interface flange into the wall of the pipe/transport system.
Temperature:
150C (302F)
Pressure:
Vacuum > 1 torr, Pressure < 3000 PSI
Lens:
Sapphire; Diameter 45 mm, thickness 12 mm, w. food

grade EPDM O-ring seal
Hygiene:
USDA, Dairy
Pipe flowcells:
Fits directly into GEA Tuchenhagen Varinline Access units (DN40 to DN150 with 68 mm opening)
Transport system: Stainless steel welding flange

Direct light:
In-line analysis of products where direct contact with the product is not a technically feasible
solution i.e. product transported on a conveyer belt.
Lens:

Hygiene:
Distance:
Scanning area:

Sapphire; Diameter 45 mm, thickness 12 mm, w. food grade


EPDM O-ring seal
USDA, Dairy
100 250 mm to sample surface
20 85 mm

Powder probe:
In line analysis of fine powder like dairy powders etc. The powder probe interface can easily be
installed into a hopper or pipe with free falling product. The probe has no moving parts. The
probe is automatically cleaned with compressed air before each analysis.
Material:
Diameter:
Length:
Fiber:
Air:
Temperature:
Installation:
Hygiene:
Cleaning:

Teflon (PCTFE)
1
7
Steel armoured fiber bundle (1, 3, 5 or 10 meters)
Clean compressed air 43 72 PSI
Max 120C
1 Swagelok crimp fitting
USDA, Dairy
Wash in water, hot or cold depending on product

Lateral transmittance:
In line analysis of slurries and viscous products such as WPC, Cream Cheese, Mozarella
etc. The Lateral transmittance probe does not restrict the flow rate of the product and
can easily be installed in the production line using a standard GEA Tuchenhagen flowcell for installation in a pipe or by welding an interface flange into the wall of a tank.
Materials:
Lens:
Temperature:
Pressure:
Hygiene:
Optical fiber:
Pipe flowcells:

Tank:

Stainless steel
Sapphire, 5 mm thick, with food grade EPDM O-ring seal
Max 150C (302F)
10bar, 145 PSI
USDA, Dairy
Steel armoured fiber bindle (1, 3, 5 or 10 meters)
Fits directly into GEA Tuchenhagen Varinline Access units
(DN40 to DN150, 1 to 6 with 68 mm opening or DN 25, 1 with 50 mm opening)
Stainless steel welding flange.

Standards and approvals


ProFoss is CE labeled and complies with the following directives:

FOSS
Foss All 1
DK-3400 Hilleroed
Denmark
Tel.: +45 7010 3370
Fax: +45 7010 3371
info@foss.dk
www.foss.dk

P/N 1026666, Issue 1GB, September. 2012

EMC Directive (2004/108/EC)


Low Voltage Directive (LVD) (2006/95/EC)
RoHS Directive (2002/95/EC)
Packaging and packing and waste Directive (94/62/EC)
WEEE Directive (2002/96/EC)
EN 60079-0:2009 - Explosive atmospheres - Part 0: Equipment - General requirements
EN 60079-31:2009 - Explosive atmospheres - Part 31: Equipment dust ignition protection by enclosure t
REACH Directive (1907/2006/EC)
Developed and produced according to FOSS ISO approval ISO 9001

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